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FMI PTW72 Manual

Welding machine for 72" wide webs
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Franklin Manufacturing Inc.
* Job# F3138 *
Model# PTW72 Horizontal
Welding Machine For 72" Wide Webs
Serial# 2724-A819600
PO Drawer 998 / Russellville, AL. 35653 / (256) 332-6654
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Summary of Contents for FMI PTW72

  • Page 1 Franklin Manufacturing Inc. * Job# F3138 * Model# PTW72 Horizontal Welding Machine For 72" Wide Webs Serial# 2724-A819600 PO Drawer 998 / Russellville, AL. 35653 / (256) 332-6654 To Table of Contents...
  • Page 2 DETAILED WARRANTY Franklin Manufacturing, Inc. warrants the machine tools and systems manufactured and shipped by Franklin to be free from defects in material and workmanship for twelve (12) months from shipment date from Seller’s factory or 2000 operating hours which ever comes first provided: (a) they are used only by the original Buyer, (b) they are given normal and proper usage, care and maintenance as specified by Seller, (c) all electrical and mechanical connections are made in accordance with Seller’s specifications, and (d) proper installation and start up procedures are employed by qualified personnel (in the case of CNC units, only Franklin...
  • Page 3 CONTENTS Introduction: Operation & Maintenance Manual Terms & Conditions of Sale FMI Equipment Sheet Section #1: Operation & Maintenance Section #2: Assembly & Parts List Section #3: Electrical Information Section #4: Hydraulic Power Unit Information Section #5: Pneumatic Information...
  • Page 4 Warning: The hydraulic power unit must be locked off before performing any maintenance or tool change. Keep hands clear from any moving object on the machine. Safety glasses are recommend for operators or anyone near the machine during operation. Operating and Maintenance Manual This manual contains essential information regarding recommended operational and maintenance procedures.
  • Page 5 (b) Subject to change without notice at any time prior to acceptance of purchaser’s order by seller’s home office, as evidenced by seller’s formal acknowledgment. (c) Firm upon seller’s acceptance of purchaser’s order as evidenced by seller’s formal acknowledgment unless escalation terms are included in terms of sale. (d) Prices do not include sales, use, excise, or similar taxes.
  • Page 6 Section #1: Operation and Maintenance Operation & Console Functions Web Splice Station Console Figure 1 Web Splice Button Layout a. E-STOP/CONTROL POWER - Removes AC power to all PLC outputs. Pull UP to enable. b. INFEED Off/On - A selector switch that controls power to the infeed conveyor.
  • Page 7 f. Outfeed Control Web\Tack Placing switch in the Web position will allow control of the outfeed conveyor at the web splice station control panel. Placing switch in the Tack position will allow control of the outfeed conveyor from the Tack station control panel. g.
  • Page 8 To Table of Contents...
  • Page 9 Franklin Tack Station a. E-STOP/CONTROL POWER - Removes and restores power to all control functions of the machine. Pulling UP fully on the button will start the hydraulic unit and enable all functions of the machine. Push in on the button to stop the hydraulics and disable all machine functions.
  • Page 10 enables control of the outfeed conveyor from the pull thru welder control panel. r. Web Outfeed – Use to control the direction of the outfeed conveyor. Pull Thru Welder Controls Pull-Thru-Welder Operator Controls a. E-STOP/CONTROL POWER - Removes AC power to all PLC outputs. Pull UP to enable.
  • Page 11 will stop when switch is released. The PTW OUTFEED switch performs the same functions for the outfeed conveyor. d. WELDER Jog - Use to bring material into weld to position for weld. Conveyors jog with this function. e. WELDER ON – This is an indicator that will be illuminated when one or both of the welders are welding.
  • Page 12 o. VACUUM UNIT - On/Off – Switching to On activates the Vacuum Unit and Off shuts Vacuum Unit down. p. TACK OUTFEED- Rev/Fwd- Use to move the tack station outfeed conveyor forward or reverse. This is used to bring the tacked beam up to the welder infeed conveyor.
  • Page 13 Manual, switching to On will activate the material cleaning brush. This switch has no function when the Brush; Manual; Auto switch is in Auto. Pull-Thru-Welder Sequence Of Operation 1. Make sure machine area clear of any obstructions, foreign materials or coworkers.
  • Page 14 Move beam forward until wire is covered with flux. Turn vacuum on. 13. To begin welding turn the weld direction selector switch to the forward position and push the start button on the NA5. NOTE: To adjust the speed of the beam use the increase and decrease buttons on the E200.
  • Page 15 sequence and turn hydraulics off. Manual operations override automatic operations. Example: When beam already has weld on bottom side copper wheels should not be used thus can be locked out by positioning switch to retract them. NOTE: See programming section to set time durations for automatic mode. PTW Programming Main Screen Speed Percent...
  • Page 16 Note: The Setup Screen may be accessed from the Main Screen by pressing the F4 button. Note: The Feet / Time Welded Screen may be accessed from the Main Screen by pressing the F3 button. Set-Up Wheel #1 On This is the time pressure wheel #1 is energized in auto mode. Wheel #1 Relax This is the time pressure wheel #1 is relaxed in auto mode.
  • Page 17 This is the distance the trailing end of the beam will travel after clearing beam reference point sensor and will turn off Head #2 welding in auto mode. In Down Time This is the time the infeed hold down is energized in auto mode. The In Down Time and the In Relax Time is used to control the frequency and the duration of the pulse.
  • Page 18 This variable records time during weld cycle. This measurement is recorded in minutes. Note: This parameter is available in manual and automatic mode. This parameter needs to be reset periodically. Note: Press F2 to reset Time Welded. Fabricator Specifications To Table of Contents...
  • Page 19 Web Splice Station Infeed Conveyor a. AC variable speed drive b. 7' wide x 45' long c. rollers 1. 3 1/2" diameter 2. 5/16" roller wall thickness 3. 18" centers d. #60 chain and sprockets Web Splice Station a. Single head welder b.
  • Page 20 #60 chain and sprockets e. 5 sets of side guide rollers f. Hydraulic web lifts @ welder entrance PTW72 Pull Thru Welder a. 545-20Hp Hydraulic Power Unit b. automatic start function, PTW, and Outfeed drive systems b. 6" to 72” wide beams c.
  • Page 21 Safety Information & Procedures Operation of Machinery FMI equipment is designed and manufactured with consideration and cares to generally accepted safety practices and standards. The proper and safe performance of the equipment depends on the use of prudent operating, maintenance, and servicing procedures by trained personnel under competent supervision.
  • Page 22 b. Never operate the system while a safety device or guard is removed or disconnected. c. Never remove warnings that are displayed on the equipment. Torn or worn labels should be replaced. d. Do not start machines until all personnel in the area have been warned. e.
  • Page 23 accident or injury. c. Before applying power to any equipment, make certain that all personnel are clear of associated equipment. d. Do not by-pass a safety device. e. Always use proper tools for the job. f. All electrical, hydraulic, and pneumatic lockout devices should be locked in the OFF position with a zero energy state before attempting to service &...
  • Page 24 Yellow shall be the basic color for designating caution and for marking physical hazards such as: Striking against, stumbling, falling, tripping, and "caught in between." Solid yellow , yellow and black stripes, yellow and black checkers (or yellow with suitable contrasting background) should be used interchangeably, using the combination which will attract the most attention in the particular environment.
  • Page 25 stickers are used on different machines so identify and be familiar with stickers on your specific machine. Pay special attention to type of sticker and its location. To Table of Contents...
  • Page 26 To Table of Contents...

  • Page 27: General Maintenance

    General Maintenance Infeed/Outfeed Conveyors a. Gear Reducer: One (1) Radicon® motor/reducer is used on each conveyor. Recommended lubricants are as follows under applying working conditions: Ambient Temp Range: 14 to 86°F ------ ISO Visc Grade#: 220 Ambient Temp Range: 32 to 113°F ---- ISO Visc Grade#: 320 Ambient Temp Range: 50 to 122°F ----- ISO Visc Grade#: 460 Mineral Oils Supplier...
  • Page 28 Flux Recovery Equipment (on Weld Splice Station & Pull Thru Welder) a. Filter & Dust Bag: Particular attention should be given the filter or dust bag on flux recovery equipment. To assure efficiency and performance it is imperative that the dust bag be manually agitated at regular intervals; at least every eight (8) hours if the equipment is in continuous operation.
  • Page 29 Stop Gate Arm: The arm pivots on a shaft to allow it to drop out of the way until needed. At the pivot point there are two (2) grease fittings; one at each end of the arm. Two (2) grease fittings should be lubricated with a good lithium base grease approximately once every forty (40) hours of operation.
  • Page 30 (250) hours of operation. See tag on power unit for proper type of hydraulic oil. Various pumps are used on FMI power units; so see tag for the type of oil used in your particular units.
  • Page 31 7. Lubricate all seals. 8. Mount new cartridge. For ease of mounting, hold the cartridge away from the magnetic core until the stud is through the hole in the bottom of the element. Then slide it up to securely seat with the top of bridge. 9.
  • Page 32 FMI equipment. Maintenance from time to time should check the fabricator for loose bolts, especially parts subjected to severe shock. Size SAE Grade 5 SAE Grade 8 Clamp Assembly Torque Clamp Assembly Torque Load Load Dry Lbs Wet Lbs Wet Lbs...
  • Page 33 The schedules listed are for a standard 40 hour work week Once every eight (8) hours of operation = Daily 1> Flux Recovery Equipment a. Empty slag screen in primary tank b. Refill primary tank c. Agitate dust bag 2> Pneumatic Lubricators (check oil level) Once every forty (40) hours of operation = Weekly 1>...
  • Page 34 This procedure will help save the customer and FMI lost time and money because of sending wrong machine parts.
  • Page 35 F3138 (PTW-72 Horizontal Welding System) F3138-00 (PTW-72 Horizontal Welding System) 842385 (Conveyor Assembly) 842260 (Take Up Sub Assembly) 818100 (Seam Welder Assembly) 818101 (Main Frame Pivot Assembly) 818004 (Flux Box Assembly) 818001 (Seam Welder Platform Assembly) 818007 (Support Platform for Pull Through Welder) 842372 (Infeed Conveyor Assembly) 842451 (Datum Roller Assembly) F3110-C842 (25’...
  • Page 36 842344 (30’ Web-Lift Infeed Conveyor) 842260 (Take Up Sub Assembly) 845301 (Front Web Lifter) 819600 (72” Material PTW Assembly) 819608 (Intermediate Web Support Roller Assembly) 819585 (Wire Spool Turntable) 819300 (Main Frame Assembly) 819315 (Vacuum & Recovery Tank Mtg.) 819332 (Horizontal Infeed Roller Assembly) 819601 (Carriage Lift Assembly w/ Tilt) 819425 (Infeed Web Lift Assembly) 819430 (Infeed Web Lift Assembly)
  • Page 37 To Mechanical Drawings...
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  • Page 47 4. WELDMENTS 30'-0" >< 60'-0" = +/- 1/8 THIRD ANGLE 4. x / xx = +/- 1/64 SEMI-ROUGH THIS PRINT IS THE PROPERTY OF FMI, INC. AND MUST BE RETURNED UPON DEMAND. THE POSSESSION AND INFORMATION THEREON OF THIS DRAWING SIZE SCALE DWG NO °...
  • Page 48 To Mechanical Drawings...
  • Page 49 4. x / xx = +/- 1/64 THIRD ANGLE SEMI-ROUGH SIZE SCALE DWG NO THIS PRINT IS THE PROPERTY OF FMI, INC. AND MUST BE RETURNED UPON DEMAND. THE POSSESSION AND INFORMATION THEREON OF THIS DRAWING ° 5. xx = +/- 1/2 deg 1000 ROUGH DOES NOT GRANT ANY RIGHTS REGARDING REPRODUCTION, MANUFACTURING, OR THIRD PARTY RIGHTS WITHOUT WRITTEN PERMISSION OF FMI, INC.
  • Page 50 To Mechanical Drawings...
  • Page 51 To Mechanical Drawings...
  • Page 52 4. x / xx = +/- 1/64 THIRD ANGLE SEMI-ROUGH SIZE SCALE DWG NO THIS PRINT IS THE PROPERTY OF FMI, INC. AND MUST BE RETURNED UPON DEMAND. THE POSSESSION AND INFORMATION THEREON OF THIS DRAWING 5. xx ° = +/- 1/2 deg 1000...
  • Page 53 4. x / xx = +/- 1/64 THIRD ANGLE SEMI-ROUGH SIZE SCALE DWG NO THIS PRINT IS THE PROPERTY OF FMI, INC. AND MUST BE RETURNED UPON DEMAND. THE POSSESSION AND INFORMATION THEREON OF THIS DRAWING 5. xx ° = +/- 1/2 deg 1000 ROUGH DOES NOT GRANT ANY RIGHTS REGARDING REPRODUCTION, MANUFACTURING, OR THIRD PARTY RIGHTS WITHOUT WRITTEN PERMISSION OF FMI, INC.
  • Page 54 To Mechanical Drawings...
  • Page 55 To Mechanical Drawings...
  • Page 56 To Mechanical Drawings...
  • Page 57 4. x / xx = +/- 1/64" SEMI-ROUGH SIZE SCALE DWG NO THIS PRINT IS THE PROPERTY OF FMI, INC. AND MUST BE RETURNED UPON DEMAND. THE POSSESSION AND INFORMATION THEREON OF THIS DRAWING ° 5. xx = +/- 1/2 deg...
  • Page 58 To Mechanical Drawings...
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  • Page 71 4. x / xx = +/- 1/64" SEMI-ROUGH SIZE SCALE DWG NO THIS PRINT IS THE PROPERTY OF FMI, INC. AND MUST BE RETURNED UPON DEMAND. THE POSSESSION AND INFORMATION THEREON OF THIS DRAWING ° 5. xx = +/- 1/2 deg...
  • Page 72 To Mechanical Drawings...
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  • Page 86 4. x / xx = +/- 1/64 Third Angle Semi-Rough Weight Size Scale Dwg #: This print is the property of FMI, Inc. and must be returned upon demand. The possession and information theron of this drawing 5. xx ° = +/- 1/2 deg Rough 1000 does not grant any rights regarding reproduction, manufacture, or third party rights without written permission of FMI, Inc.
  • Page 87 To Mechanical Drawings...
  • Page 88 To Mechanical Drawings...
  • Page 89 4. x / xx = +/- 1/64 THIRD ANGLE SEMI-ROUGH SIZE SCALE DWG NO THIS PRINT IS THE PROPERTY OF FMI, INC. AND MUST BE RETURNED UPON DEMAND. THE POSSESSION AND INFORMATION THEREON OF THIS DRAWING 5. xx ° = +/- 1/2 deg 1000...
  • Page 90 4. x / xx = +/- 1/64 SEMI-ROUGH SIZE SCALE DWG NO THIS PRINT IS THE PROPERTY OF FMI, INC. AND MUST BE RETURNED UPON DEMAND. THE POSSESSION AND INFORMATION THEREON OF THIS DRAWING ° 5. xx = +/- 1/2 deg...
  • Page 91 4. x / xx = +/- 1/64 SEMI-ROUGH SIZE SCALE DWG NO THIS PRINT IS THE PROPERTY OF FMI, INC. AND MUST BE RETURNED UPON DEMAND. THE POSSESSION AND INFORMATION THEREON OF THIS DRAWING 5. xx ° = +/- 1/2 deg...
  • Page 92 4. x / xx = +/- 1/64 SEMI-ROUGH SIZE SCALE DWG NO THIS PRINT IS THE PROPERTY OF FMI, INC. AND MUST BE RETURNED UPON DEMAND. THE POSSESSION AND INFORMATION THEREON OF THIS DRAWING ° 5. xx = +/- 1/2 deg...
  • Page 93 4. WELDMENTS 30'-0" >< 60'-0" = +/- 1/8 THIRD ANGLE 4. x / xx = +/- 1/64 SEMI-ROUGH THIS PRINT IS THE PROPERTY OF FMI, INC. AND MUST BE RETURNED UPON DEMAND. THE POSSESSION AND INFORMATION THEREON OF THIS DRAWING SIZE SCALE DWG NO 5. xx °...
  • Page 94 To Mechanical Drawings...
  • Page 95 To Mechanical Drawings...
  • Page 96 To Mechanical Drawings...
  • Page 97 Section #3: Electrical Information PTW Manual Tack Station Manual Web Material Handling Manual Electronic Parts/User Guides To Table of Contents...
  • Page 98 To Section #3...
  • Page 99 Input / Output Listing Job# Date Released: Type Function Slot Address Location Analog Output Module (4 Channel) Analog Output Ch - 1 Hydraforce Valve Ch-1 Infeed Variable Frequency Drive Speed Analog Output Ch - 2 Ch-2 Outfeed Variable Frequency Drive Speed Analog Output Ch - 3 Ch-3...
  • Page 100 24V DC-Input Console 24V DC-Input Selector - Outfeed Ground Shoes Ground Console 24V DC-Input Selector - Outfeed Ground Shoes Off Console 24V DC-Input Selector - Infeed Conveyor Run Console 24V DC-Input Selector - Infeed Conveyor Jog Console 24V DC-Input Selector - Outfeed Conveyor Run Console 24V DC-Input Selector - Outfeed Conveyor Jog...
  • Page 101 120V AC-Output 1020 Hyd Valve - Electrode #2 Weld Hyd Unit 120V AC-Output 1021 Hyd Valve - Electrode #2 Up Hyd Unit 120V AC-Output 1022 Hyd Valve - Pressure Wheel #1 Close Hyd Unit 120V AC-Output 1023 Hyd Valve - Pressure Wheel #1 Open Hyd Unit 120V AC-Output 1024...
  • Page 102 Page 1 of 10 Cable Listing Job# F3138 - PTW Released Date: H-AC AC Cable 16/30C Main Panel to Hydraulic Unit Wire Color BROWN Central Point Ground AC Neutral YELLOW Control Power Neutral Control Power BLUE Hyd Unit E-Stop E-stop Power 201A Hyd Unit E-Stop Control Power...
  • Page 103 Page 2 of 10 Cable Listing Job# F3138 - PTW Released Date: JAVAC 16 / 12C Main Panel to Air Valves Wire Color BROWN Central Point Ground AC Neutral YELLOW Control Power Neutral Control Power BLUE 1034 Flux Valve #1 Extend Control Power 1035 Flux Valve #2 Extend...
  • Page 104 Page 3 of 10 Cable Listing Job# F3138 - PTW Released Date: MPAOP 16 / 30C Main Panel to Operator Station Wire Color BROWN Central Point Ground AC Neutral YELLOW Control Power Neutral Control Power BLUE 203E E-Stop String E-stop Power 205A E-Stop String Control Power...
  • Page 105 Page 4 of 10 Cable Listing Job# F3138 - PTW Released Date: ODC1 16 / 30C Main Panel to Operator Station Wire Color BROWN Central Point Ground YELLOW Input Power Supply 0V +24V DC BLUE Input Power Supply +24V DC Control Power Button - Carriage Up Control Power...
  • Page 106 Page 5 of 10 Cable Listing Job# F3138 - PTW Released Date: ODC2 16 / 30C Main Panel to Operator Station Wire Color BROWN Central Point Ground (TPS) YELLOW Input Power Supply 0V (TPS) Weld Head Height Joystick Power Supply BLUE +24V DC Selector - Infeed Conveyor Jog/Run...
  • Page 107 Page 6 of 10 Cable Listing Job# F3138 - PTW Released Date: NA51DC NA5-1 to Console Wire Color 500-1 500-1 NA51DC Black 581A-1 581A-1 Blue 582-1 582-1 NA52DC NA5-2 to Console Wire Color NA52DC 500-2 500-2 NA52DC Black 581A-2 581A-2 NA52DC Blue 582-2...
  • Page 108 Page 7 of 10 Cable Listing Job# F3138 - PTW Released Date: Main Panel to Outfeed Box (JB3) OFCES 16 / 4C *No Power Brush* Wire Color AC Neutral BLACK E-Stop Control Power BLUE 203A E-Stop E-stop Power Control Power ORANGE Main Panel to Outfeed Box (JB3) OFCES...
  • Page 109 Page 8 of 10 Cable Listing Job# F3138 - PTW Released Date: Blue Motor Power 3138_PTW_data.xls - 3/10/2006 - 2:54 PM PTW Table of Contents...
  • Page 110 Page 9 of 10 Cable Listing Job# F3138 - PTW Released Date: PTICM 12/4C Main Panel to Infeed Conveyor Motor Wire Color Orange Ground Black S5-4T1 Motor Power S5-4T2 Motor Power Blue S5-4T3 Motor Power PTOCM 12/4C Main Panel to Outfeed Conveyor Motor Wire Color Orange Ground...
  • Page 111 Page 10 of 10 Cable Listing Job# F3138 - PTW Released Date: 3/C Shielded MITS2 Mitsubishi E200 To Program Terminal Belden 8771 Wire Color Black See Sheet 470053 See Sheet 470053 See Sheet 470053 Main Console to Infeed Conveyor IFCES 16/1C E-Stop Wire Color...
  • Page 112 Drawing Log PTW Drawing Log Dwg Number Description 470005 Main Power, Motors, & Transformers 470007 Control Power Fusing Layout 470008 Isolatton Power Fusing E-Stop, MCR, Misc. Controls & Hydraulic Control 470009 Circuit 470010 PLC Power & Torch Controls 470012 Analog Out Module 470014 Welder Speed Reference 470017...
  • Page 113 PTW Drawing Log...
  • Page 114 PTW Drawing Log...
  • Page 115 PTW Drawing Log...
  • Page 116 PTW Drawing Log...
  • Page 117 PTW Drawing Log...
  • Page 118 PTW Drawing Log...
  • Page 119 PTW Drawing Log...
  • Page 120 PTW Drawing Log...
  • Page 121 PTW Drawing Log...
  • Page 122 PTW Drawing Log...
  • Page 123 PTW Drawing Log...
  • Page 124 PTW Drawing Log...
  • Page 125 PTW Drawing Log...
  • Page 126 PTW Drawing Log...
  • Page 127 PTW Drawing Log...
  • Page 128 PTW Drawing Log...
  • Page 129 PTW Drawing Log...
  • Page 130 PTW Drawing Log...
  • Page 131 PTW Drawing Log...
  • Page 132 Material Listing Level 2 Level 3 Level 4 Level 6 Level 7 Level 8 Level 10 PTW Table of Contents...
  • Page 133 Page 1 of 9 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 000-30 Power dist. term block. Six 2 Bussman 16371 thru 14 AWG and three 1/0 16371 Power Distribution Block 6/18/03 thru 14 connections 3 Pole power dist.
  • Page 134 Page 2 of 9 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 005-06C Constant Voltage Regulator Automatio 2 pole fuse block lever DN-FAP2 406132 Primary Fuse Block 2 pole 6/18/03 n Direct assembly 005-07...
  • Page 135 Page 3 of 9 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 005-15B Automatio 30 Amp - 1 Pole - 600V, Class PTW Infeed Conveyor DN-FM6L 406131 1/19/05 n Direct CC Midget Fuse Block w/ LED...
  • Page 136 Page 4 of 9 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 005-21C Automatio 3 pole fuse block lever PTW Brush Motor Fuse DN-FAP3 406133 1/19/05 n Direct assembly Blocks 3 Pole Kit 005-22A...
  • Page 137 Page 5 of 9 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 007-09A Automatio 600V,30 Amp,20-6 AWG, Fuse DN-F6 406122 PLC Outputs Fuse Block 6/18/03 n Direct Block. 1/4 X 1-1/4" Fuse 007-09B Ferraz...
  • Page 138 Page 6 of 9 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 009-20 CK7-30- CK7-30- Sprecher+ 11-120- 11-120- Hydraulic Pump Motor Starter, 23 - 32 Amps 1/19/05 Schuh AH32A- AH32A- Starter 009-25 E233- Hour Meter...
  • Page 139 Page 7 of 9 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 010-12A Automatio 600V,30 Amp,20-6 AWG, Fuse 24V DC Power Supply Fuse DN-F6 406122 6/18/03 n Direct Block. 1/4 X 1-1/4" Fuse Block...
  • Page 140 Page 8 of 9 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 027-07B Din Rail Mount 1 Pole Relay PTW Outfeed Conveyor - Idec SH1B-05 409201 1/19/05 Base Drive Forward Relay Base 027-08A RH1B-U-...
  • Page 141 Page 9 of 9 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 051-20B Din Rail Mount 1 Pole Relay Idec SH1B-05 409201 Weld Run #1 Relay Base 6/18/03 Base 051-21A RH1B-U- Idec 1PDT Relay - 120VAC Coil...
  • Page 142 Page 1 of 7 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 007-15A Industrial Single Pole Toggle Industrial Single Pole Grainger 1X969 1X969 6/18/03 Switch - 15A Toggle Switch - 15A 007-15B Aluminum Single Toggle...
  • Page 143 Page 2 of 7 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 009-38B Cutler Conveyor Pusher Selector 10250T2 2 NO Contact Block 403148 Hammer Contact 009-38C Cutler 10250TM Custom Engraved Legend - 404143 Outfeed Pusher...
  • Page 144 Page 3 of 7 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 017-13A Cutler 10250T13 2 Position Maintained Selector Power Brush Off/On 403300 Hammer Switch - Knob Operator Selector Switch 017-13B Cutler Power Brush Off/On...
  • Page 145 Page 4 of 7 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 017-22A 3 Position Lever Operator, Cutler 10250T13 Selector - Copper Wheels # Maintained. W/Knob Operator. 403302 6/18/03 Hammer 2 - Out / Weld - 3 Position...
  • Page 146 Page 5 of 7 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 018-11B Cutler Outfeed Ground Shoes 10250T2 2 NO Contact Block 403148 6/18/03 Hammer Contact 018-13A Selector Switch - PTW Cutler 10250T13 2 Position Maintained Selector...
  • Page 147 Page 6 of 7 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 021-05A Part of 017-19 Part of 017-19 021-05B Part of 017-19 Part of 017-19 021-06A Part of 017-20 Part of 017-20 021-06B...
  • Page 148 Page 7 of 7 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 053-03 Mitsubishi E200 Mitsubishi Display E200 Mitsubishi E200 Display 6/18/03 Console Standard Central Point Ground Franklin 400000 400000 Central Point Ground Plate...
  • Page 149 Page 1 of 1 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 005-14A 151464 20 Hp - 256TC - 50Hz- 3 151464 Modificati Phase Motor - C-Face - Modificati Leeson Hydraulic Pump Motor 1/19/05 w/Base modification.
  • Page 150 Page 1 of 1 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 005-17A 5 HP, 184TC, 1440 RPM, AC PTW Infeed Conveyor Leeson 131508 Motor, 50 HZ, 3 Phase. 8.1 131508 1/17/05 Motor Amps @380V...
  • Page 151 Page 1 of 2 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 005-10 FLA=2.5 Vacuum Unit Motor #1 MECH 005-12 FLA=2.5 Vacuum Unit Motor #2 MECH 007-16A Fluorescant Fixture - Dust Grainger 3GY13 3GY13...
  • Page 152 Page 2 of 2 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery MACHINE 416200- Lewis 1/2" Plastic Bushings 1/2" Plastic Bushings WIRING 1/2" Rigid Conduit 417205-R 1/2" Rigid Conduit 417100- 3/8" Sealtite 3/8" Sealtite...
  • Page 153 Page 1 of 1 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery 005-20A 5 HP, 184TC, 1440 RPM, AC PTW Outfeed Conveyor Leeson 131508 Motor, 50 HZ, 3 Phase. 8.1 131508 1/19/05 Motor Amps @380V...
  • Page 154 Page 1 of 1 Level F3138-PTW Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Delivery CABLE Insul 8 22209 Channel 22209 Channel 6/18/03 23381 End Stop 23381 End Stop 6/18/03 24767 End Clamp 24767 End Clamp 6/18/03 28239 5"...
  • Page 155 To Section #3...
  • Page 156 Page 1 of 4 Franklin Tack Station Cable Listing Job# F3138Tack Released Date: H-AC1 AC Cable 16/4C Main Console to Hydraulic Unit Wire Color ORANGE H-AC1 Central Point Ground H-AC1 Black 201A E-Stop H-AC1 201B E-Stop H-AC1 BLUE Main Panel Receptacle Main Console To Valves on Infeed J2-AC Cable...
  • Page 157 Page 2 of 4 Franklin Tack Station Cable Listing Job# F3138Tack Released Date: 12/4C THHN H-PWR AC Wire Main Panel to Hydraulic Unit Motor Wire Wire Color H-PWR AC Power Orange Gnd - Hydraulic Unit Motor Power H-PWR AC Power S5-4T1 Hydraulic Unit Motor Power H-PWR...
  • Page 158 Page 3 of 4 Franklin Tack Station Cable Listing Job# F3138Tack Released Date: 12/4C Main Panel to Infeed Conveyor Motor MTR Gnd Orange Ground MTR PWR S5-2T1 Motor Power MTR PWR S5-2T2 Motor Power MTR PWR Blue S5-2T3 Motor Power 12/4C Main Panel to Outfeed Conveyor Motor MTR Gnd...
  • Page 159 Page 4 of 4 Franklin Tack Station Cable Listing Job# F3138Tack Released Date: MPWR 14/4C Main Panel to Magnets MPWR Orange MPWR MPWR Magnet power positive MPWR Blue Magnet power Negative 3138_tack_data.xls - 3/10/2006 - 3:36 PM Tack Station Table of Contents...
  • Page 160 Drawing Log Tack Station Drawing Log Tack Station Description Dwg Number 472005 Main Power 472007 Control Power Fusing Layout 472009 Control Wiring 472012 Control Wiring F3138-Sheet 51 Infeed and Outfeed Conveyors Tack Station Table of Contents...
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  • Page 166 Material Listing Level 2 Level 3 Level 4 Level 6 Level 8 Level 10 Tack Station Table of Contents...
  • Page 167 Page 1 of 5 Level Tack Station Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 000-01A Power dist. term block. Six 2 Bussman 16371 thru 14 AWG and three 1/0 16371 Power Distribution Block 4/21/05...
  • Page 168 Page 2 of 5 Level Tack Station Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 005-11A 30 Amp - 1 Pole - 600V, Automatio Infeed Conveyor Motor Fuse DN-FM6L Class CC Midget Fuse Block 406131...
  • Page 169 Page 3 of 5 Level Tack Station Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 007-07A 600V,30 Amp,20-6 AWG, Automatio General Controls and Mtr DN-F6 Fuse Block. 1/4 X 1-1/4" 406122 4/21/05 n Direct Starters Fuse Block...
  • Page 170 Page 4 of 5 Level Tack Station Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 009-13A RH1B-U- Infeed Conveyor - Drive Idec 1PDT Relay - 120VAC Coil 409202 4/21/05 AC120V Forward Relay 009-13B Din Rail Mount 1 Pole Relay...
  • Page 171 Page 5 of 5 Level Tack Station Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 009-26A RH1B-U- Outfeed Conveyor - Drive Idec 1PDT Relay - 120VAC Coil 409202 4/21/05 AC120V Reverse Relay 009-26B Din Rail Mount 1 Pole Relay...
  • Page 172 Page 1 of 5 Level Tack Station Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 007-05A Cutler Web Magnet - On / Off 10250T1311 2 Position Selector Switch 403300 Hammer Selector 007-05B Cutler Web Magnet - On / Off -...
  • Page 173 Page 2 of 5 Level Tack Station Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 009-14D Cutler 45mm round plastic legend. 10250TRP78 404230 Console E-Stop Legend 4/21/05 Hammer Yellow with no engraving. 009-17 Cutler 10250T63 120V AC Light Module...
  • Page 174 Page 3 of 5 Level Tack Station Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 012-01A Stop Gate - Up / Down Cutler 3 Position Selector - Spring 10250T3043 403157 Selector - 3 Position Spring...
  • Page 175 Page 4 of 5 Level Tack Station Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 012-15A Cutler 3 Position Selector - Spring Datum Side, Flange Motors 10250T3043 403157 4/21/05 Hammer Return from Both Fwd / Rev Selector...
  • Page 176 Page 5 of 5 Level Tack Station Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery TACK 16 Hole Sloping Front Tack Station Operator Button OPERAT Wiegmann WPBA-16 415503 2/15/05 Pushbutton Enclosure TACK Material Listing.xls 3/10/2006 3:42 PM...
  • Page 177 Page 1 of 1 Level Tack Station Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 005-10 5 Hp - 1425 RPM - 380V - 131454 131454 184T - TEFC, 8.1 FLA, Leeson Hydraulic Pump Motor 3/24/05 W/Base.
  • Page 178 Page 1 of 1 Level Tack Station Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 005-12 5 HP, 380V, 1440 RPM, Leeson 131508 131508 Infeed Conveyor Motor 2/10/05 184TC, 8.1 FLA. 009-02A EB-E02PK E-Stop Assembly...
  • Page 179 Page 1 of 1 Level Tack Station Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 005-14 5 HP, 380V, 1440 RPM, Leeson 131508 131508 Outfeed Conveyor Motor 2/10/05 184TC, 8.1 FLA. 009-04A EB-E02PK E-Stop Assembly...
  • Page 180 Page 1 of 1 Level Tack Station Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery CONS- 16 pin male insert #1-16 for 420116- Main panel to console cable 4/21/05 CABLE cable connector parts 16 pin male insert #17-32 for...
  • Page 181 To Section #3...
  • Page 182 Page 1 of 8 Web Material Handling Cable Listing Job# F3138 3/10/2006 12C/16 Bridge Box To Lift Beam Wire Color Flex YELLOW/GRE BLACK 1 1032 RELAY TO ROW 1 MAGNET 1 BLACK 2 1033 RELAY TO ROW 1 MAGNET 2 BLACK 3 1034 RELAY TO ROW 1 MAGNET 3...
  • Page 183 Page 2 of 8 Web Material Handling Cable Listing Job# F3138 3/10/2006 12/4 SO Main Panel to Gantry Bridge Box Wire Color B166 Brake Power Magnets Positive Magnets Negative B165A Brake Power 16/6 SO Bridge Box To Lift Beam Box Wire Color Central Point Ground Control Power Neutral...
  • Page 184 Page 3 of 8 Web Material Handling Cable Listing Job# F3138 3/10/2006 12/4C Motor Power Cable - Main Panel to Wire Color Gantry Traverse GANTRY TRAVERSE MOTOR GND GANTRY TRAVERSE MOTOR S5-4T1 POWER GANTRY TRAVERSE MOTOR S5-4T2 POWER S5-4T3 GANTRY TRAVERSE MOTOR GND Power Cable - Main Panel to Outfeed 4C / 12G Wire Color...
  • Page 185 Page 4 of 8 Web Material Handling Cable Listing Job# F3138 3/10/2006 30C/16G Main Panel to Console Wire Color BROWN Central Point Ground YELLOW Control Power Neutral BLUE 154A Control Power 203B Control Power ORANGE Spare BLACK 203A Emergency Stop RED/BLACK Emergency Stop BLUE/BLACK...
  • Page 186 Page 5 of 8 Web Material Handling Cable Listing Job# F3138 3/10/2006 20C/16G Main Panel to Console Wire Color BROWN Central Point Ground YELLOW Spare BLUE Spare Spare ORANGE Spare BLACK Spare RED/BLACK Spare BLUE/BLACK Spare ORANGE/BLA Spare YELLOW/BLA JOYSTICK - GANTRY UP BLACK/RED JOYSTICK - GANTRY DN RED/BLUE...
  • Page 187 Page 6 of 8 Web Material Handling Cable Listing Job# F3138 3/10/2006 12 / 1C Mag controller to right magnets Wire Color Blue Mag power Wht/Grn Mag power 16/12C NA-5 to welder Wire Color BROWN Terminal CPG on welder YELLOW Terminal 2 on welder, Sheet 471050 BLUE Terminal 4 on welder, Sheet 471050...
  • Page 188 Page 7 of 8 Web Material Handling Cable Listing Job# F3138 3/10/2006 16C/4G Operator End Box to Rail Sense Wire Color CENTRAL POINT GROUND 303A Rail Sense Prox 303B Rail Sense Prox Opposite Operator End Box to Rail 16C/4G Wire Color Sense Orange CENTRAL POINT GROUND...
  • Page 189 Page 8 of 8 Web Material Handling Cable Listing Job# F3138 3/10/2006 16C/4G Bridge Box To Down Limit Wire Color Orange CENTRAL POINT GROUND Down Limit Black 303A Down Limit Blue Spare 16C/4G Main Panel to Flux Recovery Starter Wire Color Orange CENTRAL POINT GROUND Flux Recovery Power...
  • Page 190 Drawing Log Web Material Handling Drawing Log Dwg Number Description F3138-S05 Main Power, Motors, and Transformers 470006 Gantry Lift Motors/Magnet Controller Fuse F3110-S07 Control Power Fusing Layout & Clamp Magnets 471008 Conveyor Controls 471009 E-Stop, MCR, & HPU Wiring F3138-S10 Magnet Controller Schematics 471066 Magnetic Clamp Panel Arrangement...
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  • Page 203 Material Listing Level 2 Level 3 Level 6 Level 8 Level 9 Level 10 Web Table of Contents...
  • Page 204 Page 1 of 6 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 005-00A Wiegmann NP-4836 45" X 33" Back Panel NP-4836 Main Panel Sub-Panel 5/12/05 005-00B Cutler C361KJ4 Door Hardware - 4" Handle...
  • Page 205 Page 2 of 6 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 005-05B Control Transformer Buss AJT-45 45 Amp Time Delay Fuse - 600V 400500-45 5/12/05 Secondary Fuse 005-05C 175 Amp 2-Pole Power dist. term...
  • Page 206 Page 3 of 6 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 005-17C Automation Infeed Gantry Motor Fuse DN-FAP3 3 pole fuse block lever assembly 406133 5/12/05 Direct Blocks 3 Pole Kit...
  • Page 207 Page 4 of 6 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 007-99 End Block For Use With 406122 Automation DN-EB35 Automation Direct Fuse Block DN 406123 Fuse end barriers 5/12/05 Direct...
  • Page 208 Page 5 of 6 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 008-19A RH1B-U- Infeed Conveyor Speed Relay Idec 1PDT Relay - 120VAC Coil 409202 5/12/05 AC120V 008-19B Infeed Conveyor Speed Relay...
  • Page 209 Page 6 of 6 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 013-12A RH1B-U- Idec 1PDT Relay - 120VAC Coil 409202 Infeed Gantry Forward Relay 5/12/05 AC120V 013-12B Infeed Gantry Forward Relay...
  • Page 210 Page 1 of 3 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 008-06A Selector Switch - Web Splice Cutler 3 Position Momentary Selector - 10250T3043 403157 Outfeed Conveyor Forward & 5/12/05 Hammer Lever Operator Reverse.
  • Page 211 Page 2 of 3 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 008-18A Cutler 3 Position Selector Switch, Knob, 10250T1323 403302 Conveyor Speed - Selector 5/12/05 Hammer Cam Code 3 008-18B Cutler...
  • Page 212 Page 3 of 3 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 013-01A General P9CMN4T 4 Way Joystick 403501 Infeed Gantry Joystick 5/12/05 Electric 013-01B General Infeed Gantry Joystick P9B11VN 1NO - 1NC Contact Block...
  • Page 213 Page 1 of 1 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 005-12 5 HP, 380V, 1440 RPM, 184TC, Leeson 131508 131508 Infeed Conveyor Motor 5/12/05 8.1 FLA. 009-02A EB-E02PK E-Stop Assembly...
  • Page 214 Page 1 of 1 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 005-14 5 HP, 380V, 1440 RPM, 184TC, Leeson 131508 131508 Outfeed Conveyor Motor 5/12/05 8.1 FLA. 009-04A EB-E02PK E-Stop Assembly...
  • Page 215 Page 1 of 3 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 005-16 3 HP, 380V, 1440 RPM, 184TC, Leeson 131506 131506 Infeed Gantry Traverse Motor 5/12/05 4.7 FLA. 006-10 121277 121277...
  • Page 216 Page 2 of 3 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 013-16B Infeed Gantry Material Sensed Allen Bradley 60-1665 Heavy Duty Mounting Bracket 402305-B 5/12/05 - Light Source Mount 013-17A Infeed Gantry Material Sensed...
  • Page 217 Page 3 of 3 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery GANTRY Sealtite Fitting on Motor OZ Gedney 1/2" 90 Degree Sealtight Fittings 416200-90 5/12/05 WIRING (Power) Sealtite Fitting on Conduit for...
  • Page 218 Page 1 of 1 Level Web Seamer Sum of ITEM MFG# MFG DESCRIPTION FMI# USE DESCRIPTION DATE Total Seq Delivery 066-00A 20 x 16 x 8 Continuous Hinge Web Clamp Magnet Control Wiegman N1220168 415404 5/12/05 Enclosure Enclosure 066-00B 17 x 13 Back Panel For 20 X 16...
  • Page 219 Electronic Parts/User Guides ITW Cooling Systems FX2N-4DA Special Function Block User’s Guide SM-CYCLO Speed Reducers 22.5mm Joy Stick AAA Valves Sprecher+Schuh Compact Starter Installation Instructions for Heavy Duty Limit Switches Manual Starters Honeywell Installation Instructions for Products with Conduit Openings Installation Instructions for Safety Door Interlock Installation Instructions for 30/60 Amp, Non-Fusible/Fusible Disconnect Switches Cutler Hammer Installation Instructions—Comet Series Perfect Prox Diffuse Reflective Sensors...
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  • Page 326: General Information

    Section #4 : Hydraulic Power Unit Information Note: Power Unit must be locked OFF before any maintenance or tool change. See Section #1 for Power Unit maintenance. General Information The Franklin Hydraulic Power Unit is designed for many years of safe trouble free service.
  • Page 327 Setup Procedures When installing your FRANKLIN hydraulic power unit, several steps should be followed to insure proper installation and the resulting longevity of the machine. Mechanical - 1> Locate unit in an area that is level and will provide protection from damage such as falling debris.
  • Page 328 not speed cycle times. Alterations in Relief Valve settings will void all warranties. WARNING: Continued bottoming out of pistons at the end of its stroke will result in a high pressure flow through the relief valve; causing hydraulic fluid to Over-Heat. To Table of Contents...
  • Page 329 Hydraulic Drawings 819PNU-BRUSH (Power Brush Lift Assembly) 819PNU-P1E (Pneumatic Diagram w/ VQ Valves and Sub-D) 819HYD-H1F (Hydraulic Schematic) 819HYD-H3 (Tack Station Hydraulic Power Unit) To Table of Contents...
  • Page 330 To Hydraulic Drawings...
  • Page 331 To Hydraulic Drawings...
  • Page 332 To Hydraulic Drawings...
  • Page 333 To Hydraulic Drawings...
  • Page 334 Section #5: Pneumatic Information Note: Air Supply must be locked off before any maintenance. See Section #1 for maintenance. To Table of Contents...
  • Page 335 To Section #5...